Electronic device with resin integrated housing

ABSTRACT

Provided is an electronic device that includes a housing at least partially including a metal portion, a glass plate mounted on one surface of the housing, and a buffer disposed at least on the metal portion on one face of the housing and disposed adjacent to an edge of the glass plate.

PRIORITY

This application is a continuation of U.S. patent application Ser. No.16/057,048, filed with the U.S. Patent and Trademark Office on Aug. 7,2018, as a continuation of International Application No.PCT/KR2017/010491 filed on Sep. 22, 2017, which is based on and claimspriority to Korean Application No. 10-2016-0130918 filed on Oct. 10,2016, the entire content of each of which are incorporated herein byreference.

BACKGROUND 1. Field

The present disclosure relates to an electronic device, for example, anelectronic device that includes a combination of a glass materialportion and a metallic material portion, and a manufacturing methodthereof.

2. Description of the Related Art

Typically, the term “electronic device” refers to a device that performsa specific function according to a program incorporated therein, e.g.,an electronic scheduler, a portable multimedia reproducer, a mobilecommunication terminal, a tablet personal computer (“PC”), animage/sound device, a desktop/laptop PC, or a vehicular navigationsystem, and electronic devices include home appliances. For example, theelectronic device may output information stored therein as a sound or animage. As the degree of integration of electronic devices has increased,and super-high speed and large-capacity wireless communication hasbecome popular, with various functions recently being provided in asingle mobile communication terminal. For example, various functions,such as an entertainment function, e.g., a game function, a multimediafunction, e.g., a music/video reproducing function, a communication andsecurity function for mobile banking, a schedule management function,and an e-wallet function, are integrated in a single electronic device,in addition to a communication function.

As electronic devices, such as a mobile communication terminal that iscarried and used by an individual user, continue to become more popular,the appearance of the electronic device is diversified and refined. Acase or housing made of a metallic material may be utilized so as todiversify the appearance design and texture of the electronic device,and the case or housing may include glass or ceramic material forornamental effect.

Generally, an electronic device may include a display as an outputthereof. The display can be provided as a panel that outputs a screen,and the display panel may be disposed in the housing of the electronicdevice with the display panel being coupled to window glass, which maybe made of tempered glass to ensure scratch resistance or avoid similardamage.

However, when the window glass material is combined with a metallicmaterial housing, the possibility of cracking or breakage of the windowglass material due to an external impact may increase. For example, whenan external impact or load is applied that brings the metallic materialhousing into contact with the window glass material, and the externalimpact/load temporarily or permanently deforms the metallic materialhousing, the impact/load may crack or break the window glass material.

SUMMARY

The present disclosure has been made to address at least the problemsand disadvantages described above, and to provide at least theadvantages described below. Accordingly, an aspect of the presentdisclosure provides an electronic device and a manufacturing methodthereof in which a metal housing is utilized so that cracking andbreakage of a window glass material can be prevented while diversifyingand refining the appearance of the electronic device.

According to an embodiment, a portable communication device is providedthat includes a housing and a glass plate forming at least a part of anouter surface of the portable communication device. The housing includesa metal housing member forming a portion of an outer side surface of theportable communication device, the metal housing member including afirst metal portion and a second metal portion, a seating groove formedalong the metal housing member, and a resin member including a firstportion at least partially formed in the seating groove of the metalhousing member and a second portion formed between the first metalportion and the second metal portion. The first portion of the resinmember is at least partially exposed to an outside of the portablecommunication device between the metal housing member and the glassplate and the second portion of the resin member is at least partiallyexposed to the outside of the portable communication device between thefirst metal portion and the second metal portion. The resin member isconfigured to form another portion of an outer side surface of theportable communication device between the first metal portion and thesecond metal portion.

According to an embodiment, a portable communication device is providedthat includes a housing, a glass plate and a resin member. The housingincludes a metal housing member forming a portion of an outer sidesurface of the portable communication device, the metal housing memberincluding a first metal portion and a second metal portion, a seatinggroove formed along the metal housing member, and a resin memberincluding a first portion at least partially formed in the seatinggroove of the metal housing member and a second portion formed betweenthe first metal portion and the second metal portion, the second portionof the resin member is configured to from an insulating structurebetween the first metal portion and the second metal portion. The glassplate forms at least a part of an outer surface of the portablecommunication device. The communication module is electrically connectedto at least one of the first metal portion and a second metal portion,and is configured to transmit/receive wireless signals using the atleast one of the first metal portion and a second metal portion. Thefirst portion of the resin member is at least partially exposed to anoutside of the portable communication device between the metal housingmember and the glass plate and the second portion of the resin member isat least partially exposed to the outside of the portable communicationdevice between the first metal portion and the second metal portion.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other aspects, features and advantages of the presentdisclosure will be more apparent from the following detailed descriptiontaken in conjunction with the accompanying drawings, in which:

FIG. 1 is a block diagram of an electronic device according to anembodiment of the present disclosure;

FIG. 2 is a perspective view of an electronic device according to anembodiment of the present disclosure;

FIG. 3 is a front view of the electronic device of FIG. 2;

FIG. 4 is a cross-sectional view of the electronic device of FIG. 3;

FIG. 5 is another cross-sectional view of the electronic device of FIG.3;

FIG. 6 is a front view of a housing of an electronic device according toan embodiment of the present disclosure;

FIG. 7 is a cross-sectional view of an electronic device according toanother embodiment of the present disclosure;

FIG. 8 is a flowchart illustrating a manufacturing method of theelectronic device according to another embodiment of the presentdisclosure;

FIG. 9 is a flowchart illustrating an operation of preparing a housingin the manufacturing method of the electronic device according toanother embodiment of the present disclosure;

FIG. 10 is a flowchart illustrating an operation of forming a buffer inthe manufacturing method of the electronic device according to anotherembodiment of the present disclosure;

FIGS. 11 and 12 illustrate a state in which a first injection-moldedportion is formed in the housing in the manufacturing method of theelectronic device according to an embodiment of the present disclosure;

FIGS. 13 and 14 illustrate a state in which the housing is processed, inwhich the first injection-molded portion is formed in the manufacturingmethod of the electronic device according to an embodiment of thepresent disclosure;

FIGS. 15 and 16 illustrate a state in which a second injection-moldedportion is formed in the housing in the manufacturing method of theelectronic device according to an embodiment of the present disclosure;and

FIGS. 17 and 18 illustrate a state in which a buffer is completed in themanufacturing method of the electronic device according to an embodimentof the present disclosure.

DETAILED DESCRIPTION

As the present disclosure allows for various changes and numerousembodiments, some exemplary embodiments will be described in detail withreference to the accompanying drawings. However, the embodiments do notlimit the present disclosure to a specific implementation, but should beconstrued as including all modifications, equivalents, and replacementsincluded in the spirit and scope of the present disclosure.

Although ordinal terms such as “first” and “second” may be used todescribe various elements, these elements are not limited by the terms.The terms are used merely for the purpose to distinguish an element fromthe other elements. For example, a first element could be termed asecond element, and similarly, a second element could be also termed afirst element without departing from the scope of the presentdisclosure. As used herein, the term “and/or” includes any and allcombinations of one or more associated items.

Further, the relative terms “a front surface”, “a rear surface”, “a topsurface”, “a bottom surface”, and the like which are described withrespect to the orientation in the drawings may be replaced by ordinalnumbers such as first and second. In the ordinal numbers such as firstand second, their order are determined in the mentioned order orarbitrarily and may not be arbitrarily changed if necessary.

In the present disclosure, the terms are merely used to describe aspecific embodiment, and are not intended to limit the presentdisclosure. As used herein, the singular forms are intended to includethe plural forms as well, unless the context clearly indicatesotherwise. In the description, it should be understood that the terms“include” or “have” indicate existence of a feature, a number, a step,an operation, a structural element, parts, or a combination thereof, anddo not previously exclude the existences or probability of addition ofone or more another features, numeral, steps, operations, structuralelements, parts, or combinations thereof.

Unless defined otherwise, all terms used herein, including technical andscientific terms, have the same meaning as commonly understood by thoseof skill in the art to which the present disclosure pertains. Such termsas those defined in a generally used dictionary are to be interpreted tohave the same meanings as the contextual meanings in the relevant fieldof art, and are not to be interpreted to have ideal or excessivelyformal meanings unless clearly defined in the present disclosure.

In the present disclosure, an electronic device may be a random device,and the electronic device may be called a terminal, a portable terminal,a mobile terminal, a communication terminal, a portable communicationterminal, a portable mobile terminal, a touch screen or the like.

For example, the electronic device may be a smartphone, a portablephone, a game player, a TV, a display unit, a heads-up display unit fora vehicle, a notebook computer, a laptop computer, a tablet PC, apersonal media player (PMP), a personal digital assistants (PDA), andthe like. The electronic device may be implemented as a portablecommunication terminal which has a wireless communication function and apocket sized. Further, the electronic device may be a flexible device ora flexible display device.

The electronic device may communicate with an external electronicdevice, such as a server or the like, or perform an operation through aninterworking with the external electronic device. For example, theelectronic device may transmit an image photographed by a camera and/orposition information detected by a sensor unit to the server through anetwork. The network may be a mobile or cellular communication network,a local area network (LAN), a wireless local area network (WLAN), a widearea network (WAN), an Internet, a small area network (SAN) or the like,but is not limited thereto.

FIG. 1 is a block diagram illustrating an electronic device 20 accordingto an embodiment. The electronic device 20 may include, for example, thewhole or a portion of the electronic device 20 illustrated in FIG. 1.The electronic device 20 may include at least one controller orprocessor (e.g., an application processor AP) 21, a communication module22, a subscriber identification module 22 g, a memory 23, a sensormodule 24, an input device 25, a display 26, an interface 27, an audiomodule 28, a camera module 29 a, a power management module 29 d, abattery 29 e, an indicator 29 b, and a motor 29 c. The processor 21 maydrive, for example, an operating system or an application so as tocontrol a plurality of hardware or software components connectedthereto, and may also perform various data processing and arithmeticoperations. The processor 21 may be implemented by, for example, asystem-on-chip (SoC). The processor 21 may further include a graphicprocessing unit (GPU) and/or an image signal processor. The processor 21may include at least some components (e.g., a cellular module 22 a)among the components illustrated in FIG. 1. The processor 21 may load acommand or data received from at least one of the other components(e.g., a non-volatile memory) in a volatile memory to process thecommand and data, and may store resultant data in a non-volatile memory.

The communication module 22 may include, for example, the cellularmodule 22 a, a Wi-Fi module 22 b, a Bluetooth module 22 c, a GNSS module22 d, an NFC module 22 e, and a radio frequency (RF) module 22 f. Thecellular module 22 a may provide, for example, a voice call, a videocall, a message service, or an internet service through, for example, acommunication network. The cellular module 22 a may performdiscrimination and authentication of the electronic device 20 within thecommunication network using the subscriber identification module (e.g.,a SIM card) 22 g. The cellular module 22 a may perform at least some ofthe functions that may be provided by the processor 21. The cellularmodule 22 a may include a communication processor (CP), and at leastsome (e.g., two or more) of the cellular module 22 a, the Wi-Fi module22 b, the Bluetooth module 22 c, the GNSS module 22 d, and the NFCmodule 22 e may be incorporated in a single integrated chip (IC) or anIC package. The RF module 22 f may transmit/receive, for example, acommunication signal (e.g., an RF signal). The RF module 22 f mayinclude, for example, a transceiver, a power amp module (PAM), afrequency filter, a low noise amplifier (LNA), or an antenna. At leastone of the cellular module 22 a, the Wi-Fi module 22 b, the Bluetoothmodule 22 c, the GNSS module 22 d, and the NFC module 22 e maytransmit/receive an RF signal through one or more separate RF modules.The subscriber identification module 22 g may include, for example, acard that includes a subscriber identification module and/or an embeddedSIM, and may also include intrinsic identification information (e.g.,integrated circuit card IDentifier (ICCID)) or subscriber information(e.g., international mobile subscriber identity (IMSI)).

The memory 23 may include, for example, an internal memory 23 a or anexternal memory 23 b. The internal memory 23 a may include at least oneof, for example, a volatile memory (e.g., a DRAM, an SRAM, or an SDRAM),a non-volatile memory (e.g., a one-time programmable ROM (OTPROM), aPROM, an EPROM, an EEPROM, a mask ROM, a flash ROM, a flash memory, ahard drive, and a solid-state drive (SSD). The external memory 23 b mayfurther include a flash drive (e.g., a compact flash (CF), a securedigital (SD), a micro secure digital (micro-SD), a mini secure digital(mini-SD), an extreme digital (xD), a multi-media card (MMC), or amemory stick). The external memory 23 b may be functionally orphysically connected to the electronic device 20 through any of variousinterfaces.

The sensor module 24 may measure a physical quantity or may sense anoperating status of the electronic device 20, and convert the measuredor sensed information into electric signals. The sensor module 24 mayinclude at least one of, for example, a gesture sensor 24 a, a gyrosensor 24 b, an atmospheric pressure sensor 24 c, a magnetic sensor 24d, an acceleration sensor 24 e, a grip sensor 24 f, a proximity sensor24 g, a color sensor 24 h (e.g., RGB (red, green, blue) sensor), abiometric sensor 24 i, a temperature/humidity sensor 24 j, anillumination sensor 24 k, and an ultra-violet (UV) sensor 24 l.Additionally, or alternatively, the sensor module 24 may include, forexample, an E-nose sensor, an electromyography (EMG) sensor, anelectroencephalogram (EEG) sensor, an electrocardiogram (ECG) sensor, aninfra-red (IR) sensor, an iris sensor, and/or a fingerprint sensor. Thesensor module 24 may further include a control circuit for controllingone or more sensors incorporated therein. In a certain embodiment, theelectronic device 20 may further include a processor configured tocontrol the sensor module 24 as a portion of the processor 21 orseparate from the processor 21 so as to control the sensor module 24while the processor 21 is in a sleep state.

The input device 25 may include, for example, a touch panel 25 a, a(digital) pen sensor 25 b, a key 25 c, or an ultrasonic input device 25d. As the touch panel 25 a, at least one of, for example, acapacitive-type touch panel, a resistive-type touch panel, aninfrared-type touch panel, and an ultrasonic-type panel may be used. Inaddition, the touch panel 25 a may further include a control circuit.The touch panel 25 a may further include a tactile layer so as toprovide a tactile reaction to a user. The (digital) pen sensor 25 b maybe, for example, a portion of the touch panel, or may include a separaterecognition sheet. The key 25 c may include, for example, a physicalbutton, an optical key, or a keypad. The ultrasonic input device 25 dmay sense, through a microphone (e.g., a microphone 28 d), ultrasonicwaves that are generated by an input tool so as to confirm datacorresponding to the sensed ultrasonic waves.

The display 26 may include a panel 26 a, a hologram device 26 b, aprojector 26 c, and/or a control circuit for controlling thesecomponents. The panel 26 a may be implemented to be, for example,flexible, transparent, or wearable. The panel 26 a may be constitutedwith the touch panel 25 a and one or more modules. The panel 26 a mayinclude a pressure sensor (or a force sensor) that is capable ofmeasuring the intensity of pressure of a user's touch. The pressuresensor may be integrally implemented with the touch panel 25 a, or maybe implemented by one or more sensors separately from the touch panel 25a. The hologram device 26 b may show a stereoscopic image in the airusing interference of light. The projector 26 c may project light onto ascreen so as to display an image. The screen may be located, forexample, inside or outside the electronic device 20. The interface 27may include, for example, an HDMI 27 a, a USB 27 b, an optical interface27 c, or a D-subminiature (D-sub) interface 27 d. The interface 27 mayinclude, for example, a mobile high-definition link (MHL) interface, anSD card/multi-media card (MMC) interface, or an Infrared DataAssociation (IrDA) standard interface.

The audio module 28 may bi-directionally convert, for example, sound andelectric signals. The audio module 28 may process sound informationinput or output through, for example, a speaker 28 a, a receiver 28 b,an earphone 28 c, or a microphone 28 d. The camera module 29 a is adevice that is capable of taking, for example, a still image and a videoimage, and the camera module 29 a may include at least one image sensor(e.g., a front sensor or a rear sensor), a lens, an image signalprocessor (ISP), or a flash (e.g., LED or xenon lamp). The powermanagement module 29 d may manage, for example, the electric power ofthe electronic device 20. The power management module 29 d may include apower management integrated circuit (PMIC), a charger integrated circuit(IC), or a battery gauge. The PMIC may be configured as a wired and/orwireless charging type. The wireless charging type may include, forexample, a magnetic resonance type, a magnetic induction type, or anelectromagnetic wave type, and may further include an additional circuitfor wireless charging (e.g., a coil loop, a resonance circuit, or arectifier). The battery gauge may measure the remaining charge of thebattery 29 e, and a voltage, a current, or a temperature while charging.The battery 29 e may include, for example, a rechargeable battery and/ora solar battery.

The indicator 29 b may indicate a specific status of the electronicdevice 20 or of a part thereof (e.g., the processor 21), such as abooting status, a message status, or a charged status. The motor 29 cmay convert an electric signal into a mechanical vibration, and maygenerate, for example, a vibration or a haptic effect. The electronicdevice 20 may include, for example, a mobile TV support device (e.g., aGPU) that is capable of processing media data according to a standardof, for example, digital multimedia broadcasting (DMB), digital videobroadcasting (DVB), or MediaFlo™. Each of the components describedherein may be constituted with one or more components, and the names ofthe corresponding components may vary depending on the type of theelectronic device. The electronic device (e.g., the electronic device20) may not include some of the components, or may include an additionalcomponent. Alternatively, some of the components may be combined witheach other to be configured as one object, and to perform functions,which are the same as those of the corresponding components prior to thecombination.

FIG. 2 is a perspective view of an electronic device 100 according to anembodiment. FIG. 3 is a front view of the electronic device 100 of FIG.2.

Referring to FIGS. 2 to 3, the electronic device 100 (e.g., theelectronic device 20 in FIG. 1) includes a housing 101 and a glass plate102 mounted on at least one face of the housing 101.

The housing 101 may accommodate, for example, the electronic componentsdescribed with reference to FIG. 1, and may at least partially include ametal portion of a metallic material. For example, a part or theentirety of the housing 101 may be made of a metallic material. In someembodiments, some of the metallic material portions of the housing 101may be utilized as radiation conductors of an antenna device. Forexample, some of the metallic material portions of the housing 101 maybe connected to the communication module 22 of FIG. 1 totransmit/receive wireless signals.

The glass plate 102 may be provided as a part or the entirety of adisplay device (e.g., the display 26 in FIG. 1) of the electronic device100. For example, a display panel (e.g., the panel 26 a in FIG. 1) maybe provided on an inner face 102 a of the glass plate 102 to provide anoutput display screen. A touch panel (e.g., the touch panel 25 a inFIG. 1) may be disposed on the glass plate 102, and a touch panel and adisplay panel may be combined so as to provide a touch screen function.For example, the glass plate 102 may be an output device that at leastpartially outputs a screen, and may be utilized as an input device thatgenerates an input signal corresponding to a touch input of a user.

An input device such as a button or a touch key (e.g., the key 25 c inFIG. 1) may be provided on a lower side 102 a of the glass plate 102,and a sound module (e.g., the receiver 28 b of FIG. 1) may be providedon the upper side 102 b of the glass plate 102. The display panel may beprovided to correspond to a region of the lower side 102 a of the glassplate 102, and may be combined with a touch panel disposed on the lowerside 102 a of the glass plate 102 so as to replace a mechanicallyoperated input device, such as a button.

FIG. 4 is a cross-sectional view of the electronic device of FIG. 2 andFIG. 5 is another cross-sectional view illustrating the electronicdevice of FIG. 2.

FIG. 4 is a cross-sectional view of the electronic device 100 takenalong line A-A′ of FIG. 3, and FIG. 5 is a cross-sectional view ofanother embodiment of the electronic device 100 taken along line B-B′ ofFIG. 3.

Further referring to FIGS. 4 and 5, the electronic device 100 includesglass plate 102 having inner and outer faces which are formed at leastpartially in a curved shape, for example, a three-dimensional shape. Adisplay panel 121 is coupled to the inner face 102 a of the glass plate102, which provides a window for viewing of the display panel 121, andthe display panel 121 at least partially has a curved shapecorresponding to a shape of the inner face of the glass plate 102. Anouter face 102 b of the glass plate 102 provides a surface of a glassplate having a planar area that covers at least a part of the displaypanel 121 of the electronic device 100. The glass plate 102 (and/or thedisplay panel 121) may be bonded at least in part to the housing 101 viaan adhesive 119 (e.g., double-sided tape). The bonded portion of thehousing 101 may be formed as a curved surface corresponding to thecurved portion of the glass plate 102 and/or the display panel 121. Forexample, the adhesive 119 may bond a portion of the glass plate 102and/or the display panel 121 to a portion of the housing 101.

The electronic device 100 may include a buffer member (herein “buffer”)103. The buffer 103 may be formed of a synthetic, non-conductive resinmaterial, e.g., polycarbonate, and may be formed along a portion of thehousing 101 as a molding member. The buffer 103 may be disposed adjacentto an edge area 102 c of the glass plate 102, and may be disposedbetween the glass plate 102 and a metal portion of the housing 101comprising a metallic material, to reduce an impact or a load applied tothe glass plate 102 from transferring to the housing 101. For example,the buffer 103 is disposed adjacent to the edge area 102 c of the glassplate 102 while being disposed on at least the portion the metal portionof the housing 101 that includes a metallic material. The buffer 103 isdisposed at least on the metal portion on one face of the housing, andis disposed adjacent to the edge area 102 c of the glass plate 102 suchthat the metal portion of the housing 101 is prevented from coming intodirect contact with the glass plate 102. Rather, the edge area 102 c ofthe glass plate 102 is aligned with the buffer 103 and, if an externalimpact deforms the housing 101, the edge area 102 c of the glass plate102 directly contacts the buffer 103.

The housing 101 includes a metal portion (211, FIG. 6) and anon-metallic material portion (e.g., a synthetic resin materialportion). A portion of the buffer 103 may be formed on the metal portionand the remaining part of the buffer 103 may be formed on thenon-metallic material portion. As will be described with reference toFIG. 6, the buffer 103 may be formed in a closed curve on one face ofthe housing 101, for example, on the face of the housing 101 on whichthe glass plate 102 is mounted. For example, the buffer 103 may surroundthe region where the display panel 121 is disposed and/or the regionwhere the adhesive 119 is disposed.

When an impact is applied to the housing 101 due to being dropped or thelike, the impact may be concentrated in a certain portion. For example,when a corner portion of the housing 101 first collides with the floor,the impact may be concentrated in the corner portion. The buffer 103 maybe formed only in a portion where the impact is concentrated, or may beformed thicker in the portion where the impact is concentrated whilebeing formed to surround the portion where the display panel 121 isdisposed.

As illustrated in FIG. 4, the buffer 103 may be partially exposed to theoutside at the outside of the edge area 102 c of the glass plate 102.When the glass plate 102 and the buffer 103 are disposed as illustratedin FIG. 5, the glass plate 102 and the buffer 103 can be seen from theoutside through the edge area of the glass plate 102. For example, thebuffer 103 may provide a decorative effect to the appearance of theelectronic device 100.

The housing 101 may include a seating groove 131 (FIGS. 4 and 5) formedto correspond to at least a portion of the edge area 102 c of the glassplate 102. For example, the seating groove 131 may be formed in at leastthe metal portion of the housing 101 in a region corresponding to theedge area 102 c of the glass plate 102. The buffer 103 may be formed atleast partially in the seating groove 131.

In order to secure sufficient coupling force and/or bonding forcebetween the housing 101 (and/or the metal portion of the housing 101)and the buffer 103, a binding groove is formed in the seating groove131. As shown in FIG. 5, the binding groove includes, for example, aV-shaped groove 133 a formed in and/or recessed from the inner wall ofthe seating groove 131 and a screw hole 133 b formed in and/or recessedfrom the bottom of the seating groove 131. The buffer 103 may be formedof a synthetic resin, such as polycarbonate, and may be formed throughan insert molding method in which the metal portion of the housing 101is placed in a mold and a molten resin is injected into the mold.

In the insert injection process, the binding force between the metalportion of the housing 101 and the buffer 103 may be weak. An electronicdevice (e.g., the electronic device 100 of FIG. 2) may include at leastone binding groove formed in the seating groove 131, so that sufficientbinding force and/or bonding force can be secured between the metalportion of the housing 101 and the buffer 103. In the process of formingthe buffer 103, a portion of the buffer 103 may be formed to be engagedwith the V-shaped groove 133 a and/or the screw hole 133 b. For example,a portion of the buffer 103 is bound to the V-shaped groove 133 a andthe screw hole 133 b (and/or the screw threads in the screw hole 133 b),so that the buffer 103 dovetails with and is firmly coupled to themetallic material portion of the housing 101.

FIG. 6 is a front view of a housing 201 of an electronic deviceaccording to an embodiment.

Referring to FIG. 6, the housing 201 includes a metal portion 211comprising a metallic material and a synthetic resin material portion213, and may also include a buffer 203 formed in at least one edge ofone face of the housing 201. The housing 201 may include a metal portion211 formed of a metallic material, and may partially include a syntheticresin material portion, depending on the electronic components disposedwithin the housing 201. For example, some electronic components (ormodules), such as the proximity sensor 24 g, the illuminance sensor 24k, the receiver 28 b, and the motor 29 c in FIG. 1, may be mounted inthe housing 201. When it is necessary to form an insulating structurebetween the electronic components mounted in the housing 201 and otherstructures, the synthetic resin material portion 213 can be usefullyutilized. The synthetic resin material portion 213 may be formed betweena first metal portion 211 a and a second metal portion 211 b of thehousing 201. For example, when the first metal portion 211 a is utilizedas a radiation conductor of the antenna device, the synthetic resinmaterial portion 213 may be interposed between the first metal portion211 a and the second metal portion 211 b of the metallic materialportion 211 to form an insulating structure.

The synthetic resin material portion 213 may be formed of polycarbonateor the like. When necessary to secure strength in a similar level to themetal portion 211, the synthetic resin material portion 213 may beformed of a synthetic resin to which glass fiber is added. The contentof glass fiber in the synthetic resin material portion 213 or the likemay be appropriately adjusted in consideration of the kind of thesynthetic resin and the strength required for the housing 201. Forexample, when the synthetic resin material portion 213 is formed ofpolycarbonate and the metal portion 211 is formed of aluminum, thesynthetic resin material portion 213 may include glass fiber in anamount of about 40%.

As shown in FIG. 6, the buffer 203 may be formed in a closed curve onone face of the housing 201. For example, the buffer 203 may extendalong an edge of one face of the housing 201, and may be disposedadjacent to an edge area of a glass plate 102 mounted on one face of thehousing 201. When the buffer 203 forms the closed curve, theabove-described seating groove 131 may be formed in one face of thehousing 201 to extend (to be formed) along the edge of the face. Thebuffer 203 may be formed only in a portion of the closed curve where theimpact is concentrated, or may be formed thicker in the portion of theclosed curve where the impact is concentrated while being formed in aclosed curve.

FIG. 7 is a cross-sectional view illustrating an electronic device 300according to an embodiment.

Referring to FIG. 7, the electronic device 300 may include a glass plate302 having a planar area 328 of a surface thereof and at least a of thewindow glass plate 302 forming a curved face 329 portion that cures awayfrom the planar area 328. The outer surface of the glass plate 302 formsat least one portion of an outer surface of the electronic device 300.For example, the glass plate 302 may have an edge area formed in acurved shape, and may be coupled to the housing 301 with the displaypanel 321 interposed adjacent to the glass plate 302. The housing 301includes a metal portion generally formed of a metallic material, andincludes a buffer 303 disposed adjacent to the edge area of the glassplate 302 in a seating groove 331. The buffer 303 includes a bindinggroove 333 formed to secure within a similarly shaped recess of thehousing 301. For example, the buffer 303 may be formed as a portion ofthe housing 301, and may be disposed at least between the edge area ofthe glass plate 302 and the metal portion of the housing 301. To affixthe glass plate 302 and/or the display panel 321 on the housing 301, anadhesive member 319 may be used to bond a portion of the glass plate 302onto the housing 301.

FIG. 8 is a flowchart illustrating a manufacturing method of theelectronic device according to an embodiment. FIG. 9 is a flowchartillustrating an operation of preparing a housing in the manufacturingmethod of the electronic device according to an embodiment. FIG. 10 is aflowchart illustrating an operation of forming a buffer in themanufacturing method of the electronic device according to anembodiment.

FIGS. 11 and 12 illustrate a state in which a first injection-moldedportion is formed in the housing in the manufacturing method of theelectronic device according to an embodiment. FIGS. 13 and 14 illustratea state in which the housing is processed in which the firstinjection-molded portion is formed in the manufacturing method of theelectronic device according to an embodiment. FIGS. 15 and 16 illustratea state in which a second injection-molded portion is formed in thehousing in the manufacturing method of the electronic device accordingto an embodiment. FIGS. 17 and 18 illustrate a state in which a bufferis completed in the manufacturing method of the electronic deviceaccording to an embodiment.

Referring to FIG. 8, a manufacturing method of an electronic device 100includes, in step 401, preparing a housing, which is at least partiallyformed of a metallic material. In step 402 a buffer 203 is formed on oneface of the prepared housing, and in step 404 a glass plate 102 ismounted on one face of the housing, which is formed with the buffer.When the glass plate is mounted on the housing, a buffer may be disposedat least between the metallic material portion of the housing and theedge area of the glass plate. For example, the buffer may be disposedadjacent to the edge area of the glass plate while being disposed atleast in the metal portion of the housing.

Referring to FIG. 9, preparing the housing includes forming, in step411, the metallic material portion and processing a seating groove instep 415. When necessary to partially isolate the metallic materialportion of the housing and/or a portion between the housing to be formedand an electronic component, preparing the housing further includes step413 that is performed after step 411 of forming a first injection-moldedportion before processing the seating groove of step 415.

The step 411 of forming the metallic material portion is an operationfor forming the metallic material portion of the housing to bemanufactured, and may be performed through a die-casting process. Themetallic material portion of the housing to be manufactured may beformed of, for example, aluminum. In some embodiments, the forming ofthe metallic material portion may include cutting a flat aluminum platehaving a predetermined thickness.

The step 413 of forming the first injection-molded portion may beperformed when it is necessary to form an insulating portion in thehousing to be manufactured. The step 413 of forming the firstinjection-molded portion may be performed through an insert injectionprocess in which a molten resin is injected while the formed metallicmaterial portion is disposed in the mold. The molten resin injected intothe mold in the step 413 of forming the first injection-molded portionmay be generally polycarbonate, and may include glass fiber in an amountof about 40%.

A housing 501 a (hereinafter, “primarily molded housing 501 a”), whichis formed with a first injection-molded portion, is illustrated in FIGS.11 and 12. As shown in FIGS. 11 and 12, a first injection-molded portion513 may be formed to partially enclose an area between a portion of ametallic material portion 511 and/or another portion thereof.

The processing of the seating groove in step 415 of FIG. 9 is anoperation for processing the primarily molded housing 501 a, and mayremove, for example, an unnecessary portion of the firstinjection-molded portion 513 (e.g., a molded portion corresponding to agate or the like for injecting a molten resin), or may form a seatinggroove in one face of the primarily molded housing 501 a. The operationfor forming the seating groove may be performed, for example, through acutting process using a computer controlled lathe or the like, and aseating groove may be formed in an edge area of one face of theprimarily molded housing 501 a. A housing 501 b (hereinafter, “primarilyprocessed housing 501 b”), which is formed with a seating groove, isillustrated in FIGS. 13 and 14. Referring to FIGS. 13 and 14, a seatinggroove 531 is formed along the edge area on one face of the primarilyprocessed housing 501 b to form, for example, a closed curve. Processingthe seating groove 531 includes removing a portion of the firstinjection-molded portion 513. A binding groove (e.g., the V-shapedgroove 133 a or the screw hole 133 b in FIG. 5) may be formed in theinner wall and/or the bottom of the seating groove 531 when the seatinggroove 531 is formed in step 415 of FIG. 9.

Further referring to FIGS. 8 and 10, forming the buffer in step 402 mayinclude forming the second injection-molded portion of step 421 of FIG.10 and the processing step 423 of the second injection-molded portion.Forming the second injection-molded portion may form the secondinjection-molded portion by injecting a molten resin (e.g.,polycarbonate) in a state in which the primarily processed housing 501 b(FIG. 14) is seated in the mold. For example, the secondinjection-molded portion may be formed in the seating groove 531 in theprimarily processed housing 501 b. A housing 501 c (hereinafter,“secondarily molded housing 501 c”), which is formed with a secondarilyinjection-molded portion, is illustrated in FIGS. 15 and 16. Referringto FIGS. 15 and 16, when the molten resin is injected into the mold, asecond injection-molded portion 503 a is filled and hardened in theseating groove 531. The molten resin filled in the seating groove 531may include polycarbonate and may not contain glass fiber, so that theresin filled in the seating groove 531 may have a lower strength (e.g.,hardness) than the first injection-molded portion 513. According to someembodiments, when forming the second injection-molded portion 503 a,some of the molten resin may be injected into the above-describedbinding groove (e.g., the V-shaped groove 133 a and the screw hole 133 bin FIG. 5). For example, the second injection-molded part 503 a may bepartially engaged with the above-described binding groove while beingmolded.

The processing operation 423 partially processes and removes the secondinjection-molded portion 503 a so that the buffer can be completed in ashape corresponding to the edge area of the glass plate 102. The buffermay be formed, for example, by partially removing the secondinjection-molded portion 503 a through a cutting process using acomputer numerically-controlled lathe. For example, the buffer may be aportion of the second injection-molded portion 503 a. A housing 501 d(hereinafter, “secondarily processed housing 501 d”) in which the bufferis completed is illustrated in FIGS. 17 and 18. Referring to FIGS. 17and 18, the buffer 503 b may be formed on the metal portion 511 of thesecondarily processed housing 501 d and may be partially formed on thefirst injection-molded portion 513 (e.g., the synthetic resin materialportion 213 in FIG. 6). The buffer 503 b may be formed along the edgearea of one face of the secondarily processed housing 501 d, and mayhave a closed curve shape. The buffer 503 b may be formed of asynthetic, non-conductive resin material having a flexibility greaterthan a flexibility of the metal portion 511, and a stiffness lower thana stiffness of the metal portion 511. The buffer 503 b may be formedwith a thickness that varies along the closed curve, with the buffer 503b being thicker at one or more corners of the portable communicationsdevice, to absorb an external impact that deforms the housing and causesan edge area 102 c of the glass plate to directly contact the buffer103/503 b.

The metal portion 511 of the secondarily molded housing 501 c is alsopartially removed in the processing operation of step 423 of FIG. 10such that the housing 201 can be completed. For example, the flat outerwall S1 of the secondarily molded housing 501 c illustrated in FIG. 16has a curved shape like the outer wall S2 of the secondarily processedhousing 501 d illustrated in FIG. 18.

As described above, the processing operation of step 423 of FIG. 10 maycomplete the buffer 503 b, and complete the shape of the housing 201(FIG. 6). The process of completing the buffer 503 b and the process ofpartially removing the metal portion of the secondarily molded housing501 c are performed in separate operations. For example, the operationof processing the buffer 503 b made of a synthetic resin material andthe metal portion 511 of the secondarily molded housing 501 c may beperformed independently.

Referring to FIG. 8, the operation for mounting the glass plate in step404 couples a glass plate 102 to one face of the secondarily processedhousing 501 d, in which the glass plate may be coupled to thesecondarily processed housing 501 d through an adhesive such asdouble-sided tape.

The manufacturing method further includes a finishing process (step 403of FIG. 8) performed on the secondarily processed housing 501 d of FIG.18. The finishing process of step 403 may include, for example, asurface treatment for providing various tactile sensations on the facewhich is touched by the user, a painting or coloring treatment and adiscoloration/corrosion prevention treatment for a portion exposed tothe external environment, etc. When the manufacturing method includesthe operation for performing the finishing process of step 403, theglass plate will be coupled to the housing subjected to the finishingprocess.

As described above, according to an embodiment, an electronic device isprovided that includes a housing including a metal portion comprising ametallic material; a buffer disposed on at least one portion of themetal portion of the housing; and a glass plate forming at least oneportion of an outer surface of the portable communication device, withat least one portion of an edge area of the glass plate positionedadjacent to the buffer.

The buffer may be formed on one face of the housing to form a closedcurve.

The buffer may be formed of a synthetic resin including polycarbonate.

The housing may include a seating groove formed in one face tocorrespond to at least a portion of an edge area of the glass plate, andat least a portion of the buffer may be accommodated in the seatinggroove.

The housing may further include a binding groove formed in the seatinggroove, and a portion of the buffer may be bound with the bindinggroove.

The binding groove may include a screw hole.

The buffer may be formed on one face of the housing to form a closedcurve.

A portion of the buffer may be exposed outside the edge area of theglass plate, and at least outer face of the edge area of the glass platemay be formed to form a curved face.

The inner face and outer face of the edge area of the glass plate may beformed to form a curved face.

The electronic device may further include a display panel coupled to aninner face of the glass plate, and an adhesive that bonds a portion ofthe display panel to one face of the housing.

The buffer may be formed in a closed curve that surrounds a region whereat least the adhesive is bonded.

A method of manufacturing the above-described electronic device isprovided that includes preparing a housing, which is at least partiallymade of a metallic material, forming a buffer on one face of theprepared housing, and mounting a glass plate on the one face of thehousing in which the buffer is formed.

The buffer may be disposed at least on the metallic material portion onthe one face of the housing, and may be disposed adjacent to an edgearea of the glass plate.

Preparing the housing may include forming the metallic material portionand processing a seating groove in which the buffer is to be disposed,by processing at least the metallic material portion.

Preparing the housing may include forming a first injection-moldedportion in the state in which the formed metallic material portion isseated in a mold prior to processing the seating groove.

Processing the seating groove may include forming a binding groove inthe formed seating groove.

A portion of the buffer may be configured to be engaged in the bindinggroove.

Forming the buffer may include forming a secondarily injection-moldedportion in the state in which the prepared housing is seated in the moldand completing the buffer by processing the secondarily injection-moldedportion to correspond to an edge area of the glass plate.

The method may further include processing the housing in which thebuffer is formed prior to mounting the glass plate, with the shape ofthe buffer being completed to correspond to the edge area of the glassplate.

The method may further include finishing the processed housing afterprocessing the housing in which the buffer is formed.

The finishing operation may include coloring the surface of theprocessed housing.

According to an embodiment, the electronic device is configured suchthat a buffer is disposed at least between the metallic material portionof the housing and the edge area of the glass plate. As a result, it ispossible to prevent the glass plate from cracking or breaking even whenthe housing is temporarily or permanently deformed by an externalimpact. For example, it is possible to prevent application of an impactor a load to the glass plate since the shock applied to the housing orthe deformation of the housing is absorbed by the buffer member. Thus,it is possible to provide improved durability, reliability, and the likein the electronic device while enabling an aesthetically pleasingdesign.

In the foregoing detailed description, specific embodiments of thepresent disclosure have been described. However, it will be evident to aperson ordinarily skilled in the art that various modifications may bemade without departing from the scope of the present disclosure.

What is claimed is:
 1. A portable communication device comprising: ahousing including: a metal housing member forming a portion of an outerside surface of the portable communication device, the metal housingmember including a first metal portion and a second metal portion, aseating groove formed along the metal housing member, and a resin memberincluding a first portion at least partially formed in the seatinggroove of the metal housing member and a second portion formed betweenthe first metal portion and the second metal portion; and a glass plateforming at least a part of an outer surface of the portablecommunication device, wherein the first portion of the resin member isat least partially exposed to an outside of the portable communicationdevice between the metal housing member and the glass plate and thesecond portion of the resin member is at least partially exposed to theoutside of the portable communication device between the first metalportion and the second metal portion, and wherein the second portion ofthe resin member is configured to form another portion of the outer sidesurface of the portable communication device between the first metalportion and the second metal portion.
 2. The portable communicationdevice of claim 1, wherein a portion of the first portion of the resinmember is exposed to the outside of the portable communication devicebetween the glass plate and the second portion of the resin member. 3.The portable communication device of claim 1, wherein the second portionof the resin member extends from the first portion of the resin member.4. The portable communication device of claim 1, wherein the firstportion of the resin member, exposed to the outside of the portablecommunication device, is formed in a closed curve on one face of thehousing.
 5. The portable communication device of claim 4, wherein theresin member is formed by insert molding in which a molten resin isinjected into the seating groove such that the first portion of theresin member is configured to correspond to a curvature of an outersurface in an edge region of the glass plate and a curvature of an outersurface of the metal housing member.
 6. The portable communicationdevice of claim 1, further comprising: a binding groove formed from theseating groove into the metal housing member, and wherein a portion ofthe first portion of the resin member is fixedly engaged with thebinding groove.
 7. The portable communication device of claim 6, whereinthe binding groove includes one of a V-shaped groove and a screw hole.8. The portable communication device of claim 6, wherein the resinmember is formed by insert molding in which a molten resin is injectedinto the binding groove such that the portion of the first portion ofthe resin member is fixedly engaged with the binding groove.
 9. Theportable communication device of claim 1, wherein the glass plateincludes a planar area and at least one edge area curving away from theplanar area.
 10. The portable communication device of claim 1, whereinthe second portion of the resin member is configured to from aninsulating structure between the first metal portion and the secondmetal portion.
 11. The portable communication device of claim 1, furthercomprising: a communication module electrically connected at least oneof the first metal portion and a second metal portion, and configured totransmit/receive wireless signals using the at least one of the firstmetal portion and a second metal portion.
 12. A portable communicationdevice comprising: a housing including: a metal housing member forming aportion of an outer side surface of the portable communication device,the metal housing member including a first metal portion and a secondmetal portion, a seating groove formed along the metal housing member,and a resin member including a first portion at least partially formedin the seating groove of the metal housing member and a second portionformed between the first metal portion and the second metal portion, thesecond portion of the resin member is configured to from an insulatingstructure between the first metal portion and the second metal portion;a glass plate forming at least a part of an outer surface of theportable communication device; and a communication module electricallyconnected at least one of the first metal portion and a second metalportion, and configured to transmit/receive wireless signals using theat least one of the first metal portion and a second metal portion,wherein the first portion of the resin member is at least partiallyexposed to an outside of the portable communication device between themetal housing member and the glass plate and the second portion of theresin member is at least partially exposed to the outside of theportable communication device between the first metal portion and thesecond metal portion.
 13. The portable communication device of claim 12,wherein the resin member is configured to form another portion of anouter side surface of the portable communication device between thefirst metal portion and the second metal portion.
 14. The portablecommunication device of claim 12, wherein a portion of the first portionof the resin member is exposed to the outside of the portablecommunication device between the glass plate and the second portion ofthe resin member.
 15. The portable communication device of claim 12,wherein the second portion of the resin member extends from the firstportion of the resin member.
 16. The portable communication device ofclaim 12, wherein the first portion of the resin member, exposed to theoutside of the portable communication device, is formed in a closedcurve on one face of the housing.
 17. The portable communication deviceof claim 16, wherein the resin member is formed by insert molding inwhich a molten resin is injected into the seating groove such that thefirst portion of the resin member is configured to correspond to acurvature of an outer surface in an edge region of the glass plate and acurvature of an outer surface of the metal housing member.
 18. Theportable communication device of claim 12, further comprising: a bindinggroove formed from the seating groove into the metal housing member, andwherein a portion of the first portion of the resin member is fixedlyengaged with the binding groove.
 19. The portable communication deviceof claim 18, wherein the binding groove includes one of a V-shapedgroove and a screw hole.
 20. The portable communication device of claim18, wherein the resin member is formed by insert molding in which amolten resin is injected into the binding groove such that the portionof the first portion of the resin member is fixedly engaged with thebinding groove.